OPERATING INSTRUCTIONS
Contents
1. Grease K 3 N to DIN 51825 lithium based water resistant to DIN 51807 Part 1 grade 0 or 1 Regrease only with a similar grease e g Esso Unirex 3 Shell Alvania G 3 Esso Beacon 3 etc REPAIR INSTRUCTIONS Any repair work within the guarantee period is subject to the approval of the motor manufacturer GENERAL It is strongly recommended that only original spares be used for motor repairs It is work which do not affect the explosion protection and is therefore not subject to special regulations e g Replacement of gaskets or joints Repair or replacement of fan or fan cover Replacement of bearings Replacement of terminal board SPECIAL REPAIRS It is work which can affect the explosion protection e g work on stator or rotor windings Unless the repair is carried our by ourselves the proper execution of the work in accordance with the relevant regulations must be certified by an authorized expert According to EN 50019 or EN 50014 any repair of this kind must be stated on an additional plate permanently fixed to the motor INSTRUCTIONS FOR STORAGE OF MOTORS For prolonged storage of electric motors e g spare motors the following precautions must be observed PLACE Make sure that they are kept in a dry and dust free place with minimum vibration Ver lt 0 2 mm s damage to stalled bearings Ambient temperature 10 C to 40 C relative humidity lt 50 ROTOR LOCKING DEVICE On motors with roller2. OPERATING INSTRUCTIONS CLOZ TO Pa u ZT TOOE THREE PHASE MOTORS ag X KS is gt gt 2 2 amp LLI 4 UO UW iw a 2 Read these Operating Instructions before you transport install commission maintain or repair industrial motors or generators These symbols will draw your attention to the safety measures and additional instructions given these Operating Instructions Special instructions regarding safety and warranty Danger For reasons of protection of persons and objects all the safety measures and additional instructions given in these Operating Instructions must be strictly complied with Low voltage machines have dangerous rotating and conductive parts as well as possibly hot surfaces All transport installation commissioning maintenance and repair works have to be carried out exclusively by qualified personnel and checked by responsible experts observe A N VDE 0105 IEC 364 Inappropriate use may cause major damage to persons and objects Should additional data be required you should immediately consult the manufacturer or an authorized service workshop All work on electrical connections to the motors and generators should only be carried out by qualified personnel GENERAL INFORMATION SCOPE These instructions refer to surface ventilated three phase and AC low voltage cage induction motors and generators IP 54 and IP 55
3. bearings fix the rotor in place by means of the locking device to protect the bearings against damage due to vibration Motors shipped on vibration dampers should also be stored in this condition Where pulleys half couplings etc are already mounted on the shaft extension fit the locking device or place the motor on vibration dampers if possible Use dampers and locking device also for any future transport of the motor OPERATING INSTRUCTIONS FOR THREE PHASE SINGLE PHASE AND BRAKE MOTORS 3001 12 Ed 01 2012 3 CHECK BEFORE COMMISSIONING BEARINGS Before commissioning a motor that has been stored for more than 4 years check the bearings For motors without regreasing device grease has to be renewed or bearings have to be changed after 2 years at the latest Even minor corrosion can considerably shorten the service life of the bearings Bearings that need not be replaced N should be packed with new grease For grease type and quantity refer to the rating plate on the motor and to Bearing lubrication Lubricant on page 6 of this Operating Instructions Motors with regreasing device have to be regreased after 2 years at the latest with the double quantity of grease indicated on the nameplate Hereby the rotor has to be rotated When motors are stored for over 4 years change grease The rotor has to be rotated every month by approx 30 degrees in order to avoid compression spots on the bearings
4. to DIN VDE 0530 part 5 EN 60034 and IEC 34 5 Higher degrees of protection are indicated on the rating plate These low voltage machines are intended for industrial installations They comply with the harmonized standards DIN VDE 0530 EN 60034 Observe any possible special prescriptions for their use Air cooled low voltage machines are designed for operation at altitudes lt 1000 m above sea level and at ambient temperatures between 20 C and 40 C Exceptions are stated on the rating plate Observe especially different indications on the rating plate A N The conditions at the place of use must coincide with all the data of the rating plate The low voltage machines are components of a machine according to the Directive Machines 2006 42 CE The commissioning of this machine is forbidden until conformity of the final product with this directive is proved observe EN 60204 1 TRANSPORT Should any damage be observed after delivery of the low voltage machine at its destination these should be notified immediately to the transport company avoid commissioning LIFTING EYES Lift motors only on lifting eyes provided Do not add any A N load to the motor Lifting eyes are designed for the motor mass only Should it be necessary use appropriate cable guides ROTOR LOCKING DEVICE Motors with roller bearings are protected against bearing A N damage during transport by means of a locking device which has to be removed before p
5. d is shown first e g AM 160 8 4 With 2 separate windings In the type designation the low number of poles high speed is shown first e g AM 160 4 8 For pole changing motors please observe the wiring diagram in the terminal box of the motor SINGLE PHASE CAGE MOTORS a __ O O0 Clockwise E Anticlockwise OPERATING INSTRUCTIONS FOR THREE PHASE SINGLE PHASE AND BRAKE MOTORS 3001 12 en Ed 01 2012 4
6. due to static load For rotating the rotor loosen but not remove the locking device fitted After the rotation procedure retighten the locking device INSULATION RESISTANCE AN Before commissioning check the insulation resistance With N values lt 1kW per Volt rated voltage dry the winding Check the insulation resistance of each phase against earth by means of a hand driven generator max 630 V DC until the measured value is constant The insulation resistance of new windings is above10 MQ The resistance can be lowered considerably by moisture If at room temperature the resistance is below 0 5 MW the winding must be dried In this case the winding temperature must not exceed 80 C For drying connect the space heater or another heating device or apply an AC voltage of 5 or 6 connect in delta of the rated motor voltage to terminals U1 and V1 Repeat the measurement The motor can be put into operation when the resistance is above 0 5 MQ Insulation resistance is temperature dependent i e if the temperature is increased decreased by 10 K the resistance value is halved doubled respectively WIRING DIAGRAMS THREE PHASE CAGE MOTORS Delta connection u v2 wt wr i i eG lt L Connection to star delta starter Star connection THREE PHASE POLE CHANGING MOTORS Dahlander connection In the type designation the high number of poles low spee
7. essary consult the manufacturer Do not switch safety devices off not even when test J running In the case of doubt disconnect the machine ELETTRICAL INSULATION RESISTANCE see Check before commissioning VOLTAGE AND WINDING CONNECTION The admissible fluctuation between rated voltage and supply voltage is 5 for rated frequency 2 is allowed Observe different connection indications and data on the rating plate as well as the connection diagram in the terminal box CONNECTION Choose cable cross sections in accordance with the rated current Not used cable entries must be closed by compression glands The terminal box can be turned by 90 or 180 Work should only be carried out by qualified personnel always with the machine out of operation disconnected previously secured against starting This is also valid for auxiliary circuits e g heaters Make sure that there is no voltage The supply cables must be connected with special care to ensure permanent and reliable contact without loose cable ends use suitable terminals for the connection cables Supply cables must be stress relieved so that no cantilever loads are exerted on the terminals Ensure a good connection of the protective conductor The minimum safety distances between conductors and between those and earth should not exceed the following values lt 550 V 8 mm lt 750 V 10 mm lt 1100 V 14 mm Make sure that no foreign
8. matter is left in the terminal box and that it is clean and dry Cable entries which are not used and the terminal box itself have to be sealed dust and water tight In order to maintain the degree of protection always make sure that the original gaskets are used when closing the terminal box Connect protective conductor here For the test run without drive elements secure the key A N Before commissioning brake motors make sure that the brake is operating correctly DIRECTION OF ROTATION Normally the motors are suitable for both directions of rotation Exceptions are indicated on the rating plate by an arrow For the desired direction of rotation the stator winding is connected as follows Connection of L1 L2 L3 to Direction of rotation when viewing drive end U1 V1 W1 Clockwise W1 V1 U1 Counter clockwise Check of the direction of rotation see below REVERSING THE DIRECTION OF ROTATION Mode of starting and winding Direct on line starting and pole Exchange two supply cable changing motors with separate conductors on the terminal board windings of the motor Star delta starting and pole Exchange two supply cable changing motors with Dahlander conductors at the incoming winding supply to the contactor combination TEST To check the direction of rotation switch the properly connected but uncoupled motor quickly ON OFF Y A STARTING In order to avoid excessive transient currents and torques bef
9. n machine via a coupling the shafts must be aligned radially and axially to each other The dial gauges must be firmly secured Measurements have to be taken at four points displaced by 90 while both coupling halves are turned simultaneously ANGULAR ALIGNMENT FIG 4 Deviations are to be equalized by means of shims placed under the motor feet Permanent inaccuracies must not exceed 0 03 mm referred to a diameter of 200 mm PARALLEL ALIGNMENT FIG 5 Deviations are to be equalized by placing shims under the motor The remaining inaccuracies must not exceed 0 03 mm The adjustment of the axial clearance between the coupling halves dimension is to be effected in accordance with the coupling manufacturers specification Re check alignment with the machine at operating temperature COMBINATION OF ANGULAR AND PARALLEL ALIGNMENT FIG 6 Fig 6 shows a relatively simple method of combining the two measurements The dial gauges are inserted into the corresponding screwed or clamped flat iron holders e g by set screws Fig 4 Angular alignment Fig 5 Parallel alignment centre offset Fig 6 Parallel and angular alignment VIBRATIONS DURING OPERATION Vibration levels Ver lt 3 5 mm s lt 15 kW 4 5 mm s gt 15 kW of the coupled machine are not problematic When there are differences in comparison with normal operation such as higher temperature noise vibration determine the cause and if nec
10. ns balanced with half key means balanced with full key means no key The state of balancing of the motor is indicated on the rating plate When the motor is balanced with a half key H the coupling has also to be balanced with half key machine the overhanging visible part of the key Remove anti corrosion paint by means of a suitable solvent and grease the shaft extension Use only suitable tools to mount or pull off pulleys or couplings see Fig 1 3 heat to 80 100 C and cover with a protection against accidental contact Avoid inadmissible tension of the belts technical catalogue By no means the bearings may be subjected to any pressure or shock A N Remove fancover Fig 1 Fig 2 Fig 3 Fig 1 Mounted without with female thread Fig 2 Mounted with female thread Fig 3 Pulling off OPERATING INSTRUCTIONS FOR THREE PHASE SINGLE PHASE AND BRAKE MOTORS 3001 12 Ed 01 2012 1 SUBSTRUCTURE Make sure that the feet or flanges are safely fixed and rest positively on their entire surface Check also the exact alignment with direct coupling All motor feet must rest positively on their entire surface to avoid distortion of the motor frame Avoid resonance of the base with the turning frequency and double mains frequency Turn the rotor by hand Check the direction of rotation with the machine uncoupled see Vibrations during operation ALIGNMENT When the motor is connected to the drive
11. ore changing over from Y to A wait until the starting current of the Y stage has died down or run up has concluded e g change over when rated speed is reached OPERATING INSTRUCTIONS FOR THREE PHASE SINGLE PHASE AND BRAKE MOTORS 3001 12 Ed 01 2012 2 MOTOR PROTECTION Connect semiconductor temperature detectors to the A N release device in accordance with the wiring diagram Continuity test if necessary to be carried out by means of a measuring bridge only max 2 5 V In order to achieve full thermal protection an additional thermally delayed overload protection must be installed Fig 7 Normally fuses alone protect only the supply system not the motor Example Contactor with over current relay Thermistor protection and fuse SR RES SHE 4 MAINTENANCE Before carrying out any work on the motor disconnect it and secure it against restarting Exception In motors with greasing device regrease the bearings with the motor running Caution danger of accidents Take care not to come in contact with moving parts CLEANING Depending on the local conditions air passages should be cleaned regularly BEARING LUBRICATION A N Observance of regreasing intervals is vital for the operational reliability of the motor MAINTENANCE OF BEARINGS Ball bearing with permanent lubrication Under normal operating conditions motors can be operated for about 20 000 hours without maintenance However the maxim
12. um period of maintenance free operation is four years The ball bearings and the bearing caps should then be washed with petrol or benzene If necessary replace the bearings Fill the spaces between the balls and the roller tracks as well as the grease compartments half with grease Coat shaft bushings in the bearing caps or endshields with a thin layer of grease Permanently greased bearings 2RS and 2Z bearings cannot be washed and regreased Such bearings must therefore be replaced To dismantle the bearings use pressing screws or other appropriate devices BALL BEARINGS WITH REGREASING DEVICE AND GREASE SLINGER Regreasing interval and required quantity of grease is indicated on the rating plate Bearings and bearing caps must be washed with petrol or benzene when they have been regreased twelve times Used petrol or benzene in air tight tanks should be disposed of as special refuse with the marking Petrol or Benzene Afterwards with the outer bearing cap open but the inner cap screwed on the rotor should be turned slowly and grease pressed in through the regreasing device until approximately half the empty space between the rolling elements and the roller tracks is filled with grease bearing seats thoroughly Make sure that the bearing grease used meets the following requirements If a grease with a different soap base is to be used clean Pour point approx 190 C Ash content 4 Water content 0 3 LUBRICANT
13. utting the motor into operation Close the fixing hole by means of the plug supplied The locking device must also be used for any further transport of the motor VENTILATION The distance between air intake of the motor and walls or other machinery must be at least 1 4 of the diameter of the air intake opening Cooling air flows from the non drive end towards the drive end Air leaving the motor must not be drawn in again by the fan Keep air inlets and outlets clean provided at the mounting end so that no foreign matter can enter the ventilation hole Such protection must however not affect the cooling and air leaving the motor generator or adjacent groups must not be drawn in again For vertical shaft up designs suitable protection must be CONDENSATION DRAIN HOLES Even after installation the condensation drain holes must be at the lowest point of the motor They must be kept clean Plug drain hole after each drainage INSTALLATION AND COMMISSIONING MECHANICAL TRANSMISSION ELEMENTS A N Use elastic couplings only rigid couplings require a special bearing design When using transmission elements which provoke radial or axial shaft loads during operation e g pulleys gearwheels etc take care that the permissible loads are not exceeded Relevant data are given in the respective technical catalogue Rotors are at present dynamically balanced with half key As per DIN ISO 8821 H or blank mea
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